AUTOMATIC STORAGE and retrieval systems (ASRS) have revolutionized warehouse management by enhancing efficiency, accuracy, and speed in handling goods. While the benefits of ASRS are clear, their implementation also presents unique challenges, particularly in the context of firefighting. Firefighters encounter many challenges when they respond to fires involving ASRS. These challenges highlight the complexities and potential risks associated with these advanced storage systems involving robots.
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Overview of ASRS
ASRS is a sophisticated warehouse technology designed to automate the storing and retrieval of goods. The system uses computer-controlled machines to handle tasks such as storing, retrieving, and transporting goods within a warehouse. ASRS can significantly increase storage capacity, reduce labor costs, and enhance operational efficiency (photos 1 & 2).
Fire Risks Associated with ASRS
Although an ASRS can offer many advantages, it also poses specific fire risks that differ from the risks you’ll find in traditional warehousing systems. The integration of automated machinery, conveyors, and robotic components increases the potential for fire incidents. Common causes of fires in ASRS include electrical malfunctions; mechanical failures; and, in some cases, human error during maintenance or operation.
Lessons Learned from a Large-Loss Fire Involving an ESFR Sprinkler System
In February 2019, a fire engulfed a roughly 800,000-square-foot food distribution warehouse in the United Kingdom. The warehouse used an ASRS system for order fulfillment (photos 3 & 4). The loss of the warehouse was calculated at £110 million (about $146 million) and the fire service response was an additional £132,000 pounds (about $175,000). The post-fire analysis concluded that an electrical short in a robot’s lithium-ion battery ignited a plastic storage bin in the ASRS system. This eventually spread to the entire warehouse, causing a total loss. This fire highlighted the need for the fire service to learn about these systems and develop strategies and tactics to manage similar incidents.
Complexity of ASRS Structures
ASRS structures are intricate and often involve multiple levels of storage, conveyor systems, and robotic components. Navigating these complex structures during a firefighting operation poses challenges for firefighters, as the traditional approaches used in more straightforward warehouse layouts may be insufficient. Limited access points, confined spaces, and the need toavoid damage to expensive automated equipment further complicate firefighting efforts (photo 5).
Smoke Management Challenges
In the event of a fire in an ASRS facility, smoke management becomes a critical concern. The enclosed nature of these systems can lead to the rapid accumulation of smoke, hindering visibility and making it challenging for firefighters to locate the source of the fire. The unique design of ASRS structures may require specialized strategies for effective smoke ventilation and control.BE STRONG. BE SAFE.’
Fire Suppression in ASRS Environments
Traditional firefighting methods may prove inadequate for firefighters dealing with fires in ASRS environments. The presence of automated machinery and sensitive electronic components and the potential for water damage to goods necessitates carefully considering fire suppression methods. Water-based systems may not be suitable due to the risk of damaging valuable inventory, whilealternative suppression agents must be carefully selected to avoid collateral damage. The biggest mistake firefighters can make is shutting down the automatic fire suppression system too early.
Emergency Response Planning
Developing effective emergency response plans for ASRS facilities is a critical component of mitigating the challenges associated with firefighting. Firefighters need specialized training to understand the unique features of ASRS structures, potential hazards, and specific strategies required for safe and efficient firefighting operations. Collaborative efforts between firefighting agencies and facility managers are essential in developing comprehensive emergency response protocols.
Integration of Technology in Firefighting
As ASRS facilities rely heavily on technology, firefighting efforts must also embrace technological advancements. Robotics, drones, and advanced monitoring systems can aid firefighters in assessing the situation, locating the source of the fire, and strate- gizing effective suppression methods. Integrating technology in firefighting enhances safety and improves the overall efficiency of emergency response operations (photo 6).
These facilities often have round-the- clock operations with large numbers of operational staff. The commodities found in these fulfillment centers can range from food products to clothing and household goods. The plastic bins that hold the commodities present a significant fire load, and you can find tens of thousands of these bins in a typical arrangement.
Regulatory Compliance and Standards
Ensuring that ASRS facilities comply with relevant fire safety standards is crucial in preventing and mitigating fire incidents. Fire codes and regulations must be regularly updated to address the unique challenges ASRS technologies pose. Collaboration between regulatory bodies, industry experts, and firefighting professionals is essential to developing and implementing standards that prioritize safety in ASRS environments. In North America, building codes, for the most part, will require automatic wet sprinkler systems with central station monitoring. FM Global has created a data sheet regarding ASRS (FM Global 8-34) to guide suppression systems in ASRS warehouses.
Common Building Construction
These ASRS systems typically exist in warehouse buildings of up to 2 million square feet. Ultimately, they only occupy a small footprint within a potentially massive warehouse (photo 7). The main warehouse will often be a tilt-up concrete slab building with unprotected, open web parallel chord, steel bar-joist roof support under a metal deck roof. In North America, building codes will, for the most part, require automatic wet sprinkler systems with central station monitoring.
Training and Education for Firefighters
Given the specialized nature of ASRS facilities, training programs for firefighters must be tailored to address the challenges specific to these environments. Firefighters should have the knowledge and skills to navigate- complex structures, understand the intricacies of ASRS technology, and implement effective firefighting strategies. Continuous education and training programs ensure firefighting personnel are well prepared to respond to emergencies in ASRS facilities.
Firefighters must understand these systems, as the technology has outpaced the code industry, creating a new kind of fire problem. These ASRS systems are run mainly by robots powered by lithium-ion batteries. Fire protection engineers have designed sprinkler systems to protect the building and should be able to control these fires (photo 8). Still, the problem for firefighters is that it takes an educated and skilled approach to overhaul this type of fire. In 2020, a group of firefighters worked with FSRI to develop a safe and efficient process to extinguish, salvage, and overhaul the fire entirely.
Warehouse Management
Warehouse fires in general are once- in-a-career types of events. Now let’s add systems that we are unfamiliar with and that are difficult to navigate. We have very little experience fighting these fires, and the lessons learned are, again, likely based on a once-in-a-career experience. Warehouse fires are complex and occur in a space that essentially matches that of a high-rise building lying on its side. And these wide-open spaces arefilled with products that generate the spread of fire.
The integration of ASRS in warehouse management has undoubtedly brought about significant advancements in efficiency and productivity. However, the unique challenges associated with firefighting in ASRS environments cannot be overlooked. Addressing these challenges requires a multifaceted approach. The approach must include the following:
- Technology integration.
- Specialized training.
- Regulatory compliance.
- Collaborative efforts between industry stakeholders and firefighting professionals.
While automatic storage and retrieval systems offer many advantages, they also pose specific fire risks that differ from the risks you’ll find in traditional warehousing systems.
By understanding and proactively addressing the complexities of firefighting in ASRS facilities, we can ensure the safety of both personnel and valuable assets while we harness the benefits of automated warehouse management systems.
GEORGE HEALY is a deputy chief with the Fire Department of New York (FDNY), assigned to Division 13 in south Queens. He began his career with the FDNY in April 1991, where he worked his way through the ranks to his current position. he was operations section chief for the Governor’s Island study, which tested alternate strategies for combating wind-driven fires in 2008. he was also operations section chief for the Governor’s Island ventilation and suppression exercise in 2012. healy was on the Technical Review Panel for the horizontal ventilation and vertical ventilation studies. he is a lecturer for the FDNY high Rise symposium, the Chicago high Rise symposium, the UK Fire College symposium,and FDIC, where he was also the 2014 Opening Ceremony keynote speaker. He is an instructor for FDNY’s Battalion Chief Command Course, the Deputy Chief Development Course, and Chiefs Education Day.
SEAN GRAY is a captain with Cobb County (GA) Fire and Emergency services in Metro Atlanta and has been in the fire service since 1993. he has a bachelor’s degree in fire safety engineering and has attended the Naval Postgraduate school for homeland security. he has been a member of multiple technical panels involving fire safety research and is an appointed member of the FsRI Institute advisory Board. Gray is an NFPA committee member for Fire hose, Fire service Training, Fundamentals of Fire Control Within a structure Utilizing Fire Dynamics, Facilities for Fire training and associated Props, and Fire service health and safety. he coauthored the Fire Engineering book and DVD The Evolving Fireground. Gray has also been published in multiple fire service magazines, was an FDIC H.O.T. lead instructor, runs the Web site stopBelievingstartKnowing.com, and delivers evidence-based tactics training courses across the United states.
